Racking Safety Inspection report identifying various unsafe racking conditons

1. Racking Safety Audit Report
Prepared by
Julian Kalac, P.Eng.
6/19/2013

2. Page 2 of 12 CSLC Racking Safety Audit Report 19 June 2013
To: Grant Donnelly, Chris Hawrelak, Bob Bloomer
C.C.: Winston Shim, George Asamoah
From: Julian Kalac, P.Eng License #90505462
Date: June 19, 2013
Re: Safety Audit Report
Overview:
I am a Mechanical Engineer and a Professional Engineer (P.Eng.) with over 16 years working in the
manufacturing industry with industrial machines/equipment. My experience and training have
made me very familiar with OSHA regulations and standards.
Objective
The objective of this report is to provide an initial assessment of the Pallet Racking Safety
conditions and recommend improvement suggestions that ensure full compliance to OHSA
standards and regulations.
Referenced Standards
 CSA A344.1-05 User Guide for Steel Storage Racks
 CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks
 ANSI/ALI ALOIM-2000---Safety Requirements for Operation,
Inspection/Maintenance
Regulation 851-Industrial Establishments
Regulation 851 was developed to address the issues specific to all industrial
establishments such as factories, offices, arenas, or shops operating within Ontario. It is
for this reason that Regulation 851 covers a broad range of requirements on topics such
as industrial hygiene, machine guarding, fire prevention, confined spaces, equipment
maintenance, material handling, and protective equipment.

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Certain Sections of Regulation 851 require the preparation of a written report to provide a
permanent record regarding the occurrence of health & safety issues. In particular,
Section 7 requires preparation of a written report detailing the measures that must be
taken for compliance with the relevant provisions listed in the Table
There are 5 steps in completing a Pre-Start Health & Safety Review (PSHR)
1. Safety Audit / Risk Assessment
2. PSR (Pre –Start Safety Review)
3. Design And Installation
4. PSR Sign-Off …
5. Training and Documentation
In House Racking
The pallet racks used in the warehouse are used and have been modified from it’s original
design. No PSHR was ever conducted. The main concern is the lack of documented load
rating capacity for the racks as well as several safety violations and hazards which are
shown in the pictures taken.
I was told by the only material handler who uses the rack that the load rating is 9000
Lbs/beam, which is highly unlikely given the 1/8” thickness of the cross section and
¾” Beam Depth.
No supporting documentation was provided. Therefore if no documented load ratings are
available, a PSHR must be conducted. (see MOL flow chart on Racking PSHR)
¾”
1/8”
”

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PHSR Regulation 851, section 7
Applicable provisions
of Regulation 851
Circumstances
1. Subsections 22 (1), (2) and (4) Flammable liquids are located or dispensed in a building, room
or area.
2. Sections 24, 25, 26, 28, 31 and 32 If any of the following are used as protective elements in
connection with an apparatus:
1. Safeguarding devices that signal the apparatus to stop,
including but not limited to safety light curtains and
screens, area scanning safeguarding systems, radio
frequency systems and capacitance safeguarding
systems, safety mat systems, two-hand control systems,
two-hand tripping systems and single or multiple beam
systems.
2. The barrier guards use interlocking mechanical or
electrical safeguarding devices.
3. Clause 45 (b) Material, articles or things are placed or stored on a structure
that is a rack or stacking structure.
4. Section 63 A process involves a risk of ignition or explosion that creates a
condition of imminent hazard to a person's health or safety.
5. Section 65 The use of a dust collector involves a risk of ignition or
explosion that creates a condition of imminent hazard to a
person's health or safety.
6. Sections 87.3, 87.4, 87.5 and 88,
subsections 90 (1), (2) and (3), and
sections 91, 92, 94, 95,
A factory produces aluminum or steel or is a foundry that melts
material or handles molten material.
7. Sections 51 and 53 The construction, addition, installation or modification that
relates to a lifting device, traveling crane or automobile hoist.
8. Sections 127 and 128 This process uses or produces a substance that may result in
the exposure of a worker in excess of any occupational
exposure limits as set out in Regulation 833, 835, 836, 837, 838,
839, 840, 841, 842, 843, 844, 845 or 846 of the Revised
Regulations of Ontario, 1990.

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Issue #1 –Beam Connectors damaged due to overloaded
(double stacked)pallets
Large amount of deflection indicates overloading of the racking. Where two beams
connect at an upright, the beam connectors should be parallel.
If racking is or has been overloaded, the beam connectors may be deformed
There will also be evidence of ‘permanent set’ in unloaded beams.
Above pictures shows 6 double stacked skids ~6000Lbs sitting on racking beam
which can only hold Max 1500Lbs, causing damage and deflection
6 DOUBLE STACKED SKIDS = 6000Lbs on damaged
rack beam which can hold Max 1500Lbs

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ISSUE # 2 NO SIDE GUIDE
RAILS CREATING HIGH RISK
OF TIPPING/FALLING DOWN.
CRITICAL INJURY!!

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Locking Pins/keys are inserted into the racking to prevent the unit load from
being dislodged unless mesh decks or other form of support structure has
been designed and fitted.
Missing Locking
Pins
ISSUE # 3 OVERHANGING SKID CRUSHING INJURY
NO SAFETY PINS
No Cross
Bars

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SKID ALMOST OFF
THE RACK CRITICAL
INJURY
SHIFTED LOAD –CRUSHING
INJURY

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MOL GUIDELINE FOR PSHR—RACKING

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Racking Load Capacity

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Racking design Information needed for Load Calculations
The Canadian Standards Association has two standards that provide the information you need.
 CSA A344.1-05 User Guide for Steel Storage Racks
 CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks
1. What is the Bay Clear Entry?
Single bay racking
In situations where single rows are installed, and there is pedestrian access along the rear of the racking,
rear protection should be installed to prevent loads falling out of the back of the racking.
2. What is the racking beam section?
Open beam or a box beam? The box beam is a heavier duty beam than the open
beam, so this is crucial to the strength of the entire racking system and the
loading it can take.
11
FT
8F
T

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3. How big are the racking frames?
It is important to know the dimensions of the racking frames. The measurement
required is the Height (H) (mm) x Width (W) (mm) of the frames.
4. What is the vertical beam pitch of your racking system?
The height of each storage level, measured from the floor to the top side of each
beam. If the number of beam levels varies across the racking system, then the
load criteria will also vary.